Method of making a disk or cup rotor

ABSTRACT

A conductor blank is stamped from a metal foil and has a plurality of conductors arrayed in groups of at least two with each group starting at a respective commutator bar itself extending from an inner edge addition, and each conductor terminating at an outer edge addition. Two such blanks are laminated to a pair of concentric insulating bodies defining a gap juxtaposed with the conductors adjacent the commutator bars and with the additions extending beyond the inner and outer edges defined by the bodies. Then all but one conductor of each group is punched out at the gap, the additions are cut off, and the conductors are each connected to another conductor of another blank at the gap, and at the inner and outer edges.

[ Mar. 11, 1975 United States Patent [1 1 Lazaroiu et al.

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ROTOR METHOD OF MAKING A DISK OR CUP 970 Ke0gh.............. 972 Margrain et a1. 29/598 [75] Inventors: Dumitru Florian Lazaroiu; Sigmund Sleiher; Gheroghe Mihai Mihaiescu, all of Bucharest, Romania [73] Assignee: Institutul De Cercetare Si proiectare Pentru Industria Electrotechnica, Bucharest, Romania [22] Filed: Mar. 26, 1973 [21] Appl. No.: 345,216

[30] Foreign Application Priority Data Apr. 28, 1972 Romania................................

mutator bar itself extending from an inner edge addi- 70740 tion, and each conductor terminating at an outer edge addition. Two such blanks are laminated to a pair of [52] U.S. 29/597, 29/598, 310/236, concentric insulating bodies defining a gap juxtaposed with the conductors adjacent the commutator bars and with the additions extending beyond the inner and [51] Int. H01! 43/00 [58] Field of Search...... 29/598, 596, 597; 310/261, outer edges defined by the bodies. Then all but one conductor of each group is punched out at the gap,

the additions are cut off, and the conductors are each [56] References Cited connected to another conductor of another blank at UNITED STATES PATENTS the gap, and at the inner and outer edges.

3,193,715 7/1965 Moressee et 310/268 5 Claims, 7 Drawing Figures 1 \Illl lilllIIlill PATENTED KARI 1 I975 SHEET 2 BF 7 PATENTEBHARI 1 I975 snmnury PATENTEDMARI 1 I975 sum 5 o 7 PATHHEDHAR] 1 I975 3,869,788 sumsp y METHOD OF MAKING A DISK OR CUP ROTOR FIELD OF THE INVENTION The invention relates to a method of making a lamellar conductor rotor with separate commutator. More particularly this invention concerns the manufacture of disk armature and axial air-gap direct current electric machines, and cylindrical cup rotor and radial air ga direct current electric machines.

BACKGROUND OF THE INVENTION There are known stamped lamellar conductor rotors with no separate commutators, whose brushes ride directly on the conductors.

These rotors have the disadvantage of wearing off quite quickly in the region the brushes engage. In addition, because of the relatively numerous conductors in this region, the rotor diameter must be relatively large.

There are also known stamped lamellar conductors having two layered rotors with separate commutators, whose conductors, constituting an extension of the commutator bars, alternate with conductors without any commutator bars, so that the number of commutator bars is half the number of conductors of a layer, and a section contains two turns.

These rotors have the disadvantage that they cannot be used with machines having an even number of pole pairs and, because of the relatively great number of commutator bars, (there will be obtained) a relatively large diameter disk must be used.

OBJECTS OF THE INVENTION It is therefore an object of the present invention to provide an improved method of making a rotor having stamped lamellar conductors.

SUMMARY OF THE INVENTION The invention eliminates the abovementioned disadvantages, because the number of turns per section, as well as the ratio m between the number of conductors N and then number of commutator bars, K on a layer provided with a commutator is greater than two, and the commutator bars are relatively few so, they will be wider, and thus, the commutator is stronger and will not wear off quickly. The disk rotor diameter is relatively small the winding which is utilized is applicable to any numberp of machine pole pairs, by choosing the ratio m N/K versus p.

BRIEF DESCRIPTION OF THE DRAWING The above and other objects, features, and advantages will become more readily apparent from the following, reference being made to the accompanying drawing in which:

FIG. 1 is a partial front view of a disk rotor conductor layer;

FIG. 2 is a partial front view of a disk rotor subassem- FIG. 3 is a section through a disk rotor with commutators on all layers;

FIG. 4 is a section through a disk rotor with commutators only on two adjoining layers;

FIG. 5 is a section through a disk rotor with commutator only on the two extreme end layers;

FIG. 6 is a partial view of a cut-out layer of a cylindrical cup rotor; and

FIG. 7 is a section through a cylindrical cup rotor with commutators on all the layers.

SPECIFIC DESCRIPTION According to the invention as shown in FIGS. 1-3, the rotor with stamped lamellar conductors and commutators on all the layers is made up of an even number of identical conductive layers 1, separated by insulating layers 2 and 3,-each conductive layer containing lamellar conductors 4, and a commutator forming a conductor extension. The number of turns per section, as well as the ratio between the conductors number and the commutator bars number on a layer, is greater than two. A number of conductors on a layer is connected to commutator bars 5, and the rest of the conductors terminates at an intermediate level I without commutator bars. The conductors from different layers are welded at modes or points at the exterior level II, at points at the interior level III, and at points at the intermediate level I. The disk rotor has many commutators but the brushes ride only on one of them, which is to be found on a rotor end, and after its partial wear, the rotor is reversed, the opposite commutators being then used.

According to the invention, as shown in FIG. 4, the

rotor with stamped lamellar conductors and commutators only on two adjoining layers is made up of two identical conductive layers 1, as in the above mentioned case, the other conductive layers 6 having each of its conductors terminating at the intermediate level I, without commutator bars. The conductors of the two layers with commutator are welded at modes or points at the interior level III, and at points at the intermediate level I. Each of the other layers 6, without commutators, are welded at points at the intermediate level I. At the exterior level II the conductors of the layers are welded at points.

According to the invention, as shown in FIG. 5, the rotor with stamped lamellar conductors and commutators only on the two extreme lateral or end layers is similar to that shown in FIG. 4, except that the two conductive layers 7 with commutators are not side by side, but on the rotor extreme sides or end faces. In addition the IV intermediate level solderings between the conductors of these two layers, are placed at a smaller diameter level than the other solderings of the I intermediate level on the layers without commutators.

According to the invention, the two layer stamped lamellar conductors disk rotor or winding element is manufactured as follows:

From a conductive foil, are cut a plurality of conductive disks whose, diameters are larger than the II exterior level, the difference constituting the 8a exterior conductive addition. The empty spaces 9 between the conductors 4 and the empty spaces 10 between the commutator bars 5 are circularly stamped in the conductive disks, conductive layers being thus obtained.

On an insulating layer 2 there are bonded two conductive layers, turned by relative to each other, so that the conductor terminals at the III interior and II exterior levels correspond, thus obtaining soldered conductive layers. The insulating layer 2 is made up of two circular rings, one of them, 2a, between the levels V and VI, and the other, 2b, between the levels VII and VIII. The assembly thus obtained, is circularly stamped at the gap between the bodies 2a and 2b, by means of a punch 11 confined between the levels I and VIII and,

having a shape that will make possible a detachment of the conductors without bars 4a from the commutator bars 5. In this way, on each conductive layer are formed conductors 4b, which have commutator bars in their extension, and conductors 4a, without commutator bars. One cuts out the conductive addition 8a which surpasses the outer edge level II, and the conductive addition 8b which surpasses the inner edge level III, the unwelded rotor being thus obtained. The connections between the conductors on the two sides, are performed by longitudinal soldering at the interior level III, by longitudinal soldering at the exterior level II, and by transverse soldering at the intermediate level I, the finished rotor being thus obtained.

According to the invention, the disk rotor with lamellar conductors stamped in four or in an even greater number of layer, is manufactured as follows:

In the embodiment of FIG. 3 in which the rotor has all its conductive layers provided with a commutator, the rotor is made up of 3 rotor subassemblies, manufactured in a similar way as in the case of the two-layer r tor, with the onlydifference that, at the exterior level i II, the unwelded conductors terminals on the two layers are shifted in such a way as to overlap on the corresponding conductors terminals of the other rotor subassemblies in order to weld them together. The solderings at the interior level III and at the intermediate level I are separately performed for each of the rotor subassemblies, before assembling the rotor by soldering the independent subassemblies with intermediate insulating layers 3. The II exterior level solderings are performed after this assembling has been achieved.

In-the embodiment of FIG. 4 the rotor with stamped lamellar conductors and commutators only on two adjoining conductive layers has all its conductors of the other layers without commutator bars. These conductors terminate at the intermediate level I. The rotor subassembly made up of the two layers with commutator, is identical to that of FIGS. 1-3. The other subassemblies have an insulating layer made up of a single circular ring 2a between the levels V and VI, and the cutting out of the conductive addition which surpasses the conductors terminals is carried out at the levels I and II. The conductors of each of the rotor subassemblies without commutator are longitudinally welded at the intermediate level I, and after the rotor assembling, which is performed in exactly the same manner as in FIGS. 1-3, the longitudinal solderings at the exterior level II are accomplished.

In the embodiment of FIG. 5 the rotor with stamped lamellar conductors and commutator only on the two extreme lateral conductive layers, has the other intermediate layers as those in FIG. 4, all the conductors being without commutator bars, finished at the intermediate level I. The rotor subassemblies without commutator are manufactured as in the FIG. 4, then they are assembled by soldering, having between them insulating layers 12, thus making up the rotor package. The two conductive layers with commutators, in which the empty spaces between the conductors 9 and the combetween the levels IV and X. The punch has a shape which creates a detachment between the conductors without bars 4a, and the commutator bars 5. Thus, the intermediate level IV at which the conductors 4 a without commutator bars finish, will be below the intermediate level I of the conductors terminals on the layers without commutator. The conductive addition which surpasses the exterior II and the interior levels III is cut out. The conductors on the extreme lateral layers provided with commutator, are longitudinally welded at the interior level III, and transversely at the intermediate level IV. Then the conductors at the exterior level II are welded longitudinally.

According to the invention, the cup cylindrical rotor with stamped lamellar conductors is manufactured in the same manner as the disk rotor, except the fact that:

from a conductive foil are cut out conductive bands instead of conductive disks;

the stamping of the empty spaces between the conductors 9 and between commutator bars 10, for obtaining the conductive layers 1, is performed linearly, not circularly;

because of the conductive layer position on the cylindrical rotor, the empty spaces stamping step, performed by the same punches, is different, so that the conductive layers have various lengths, making it possible to close the cylinder during the assemblies; in this case, the conductors widths do not differ much on the various layers;

each conductive layer 1 provided with commutator bars is soldered on an insulating layer 14 made up of two insulating bands, one of them 14a, between the levels V and VI, and the other 14b, between the levels VII and VIII;

the stamping by means of a punch enclosed between the levels I and VIII, performed in order to detach the conductors 4a without commutator bars from the commutator bars 5, is made linearly, not circularly, and separately, on each of the conductive layers soldered with insulating'bands;

the cutting out, regarding the conductive layers pro- 1 vided with commutator bars, of the conductive addition which surpasses the levels II and lll,is made by following straight, not circular lines, and in addition, one cuts out the edge insulating addition, parallel with the two conductors, and with the extreme commutator bars respectively, thus, several cut-out layers are obtained.

each conductive layer without commutator bars is soldered on an insulating band 14a between the levels V and VI;

the cutting-out, regarding the conductive layers without commutator bars, of the conductive addition which surpasses the levels I and II is made by following straight, not circular, lines and, besides that, one cuts out the edge insulating addition, parallel with the two extreme conductors, thus several cut-out layers are obtained;

the two-layered unwelded rotor assembly and the unwelded rotor subassemblies for the rotors with an even number of layers more than two, all of them or only two adjoining ones provided with commutator are obtained as follows: on each lateral side of a cylinder two cut-out layers are soldered by rolling, the layers having their conductors conversely oriented, and with the insulating bands situated towards the inside of the cylinder;

the two-layered rotor assembly and the rotor subassemblies for the rotors with an even, number of layers greater than two, all of them provided with commutators, are obtained by welding the conductors at the levels lII, longitudinally, and l, transversely, and only for the two layered rotor assemblies at the II level, longitudinally;

the rotor assembly with an even number, of layers greater than two, all of them provided with commutator, is obtained by introducing the rotor subassemblies, rolled on cylinders of different diameters, ones into the others, by their soldering with intermediate insulating layers and by welding the conductors at the II lelvel, longitudinally;

the rotor subassemblies for the rotors with an even, number of layers, from which only two adjoining layers are provided with commutator bars, are obtained by performing at the unwelded rotor subassemblies the conductor welds at the I level, longitudinally;

the assembly with an even, number of layers greater than two, from which only two layers are provided with commutator bars, is obtained by introducing the rotor subassemblies, with and without commutator, rolled on different diameters cylinders, ones into the others, by their soldering with intermediate insulating layers, so that the commutator will be accessible and by welding the conductors at the ll level, longitudinally;

the rotor package for the rotors with an even number of layers, greater than two, from which the only two extreme layers are provided with commutator, is obtained by introducing the rotor subassemblies without commutator ones into the others and their soldering on insulating layers, rolled on different diameters cylinders;

the rotor assembly with an even, number of layers greater than two, from which only the two extreme layers are provided with commutator, is obtained by so]- dering, by rolling the two cut-out layers provided with commutator, which have different lengths and different stamping step of the conductors, by means of insulating layers, on the two extreme sides of the rotor package and by performing the conductor solderings on the extreme layers at the levels lll, longitudinally and IV, transversely, and the conductors solderings on all the levels at the [I level, longitudinally.

The welds number at different levels of the cylindrical cup rotor for each performing version, is the same with that of the disk rotors for the similar versions.

Regarding the cylindrical cup rotors, no matter what is the number of layers provided with commutator, one uses only one commutator, which is accessible.

We claim:

1. A method of making a rotor comprising the steps of:

stamping from a metal foil a conductor blank having a plurality of conductors arrayed in groups of at least two said conductors terminating at an inner and outer edge, and said blank terminating with an addition beyond each of said inner and outer edges, said conductors having a commutator bar formed as an extension thereof;

laminating a pair of said blanks back to back on a pair of concentric insulating bodies defining a gap juxtaposed with said conductors and adjacent said commutator bars and with said additions extending beyond associated edge of said bodies;

punching out at least every second conductor at said gap to leave only one of the conductors of each group connected to its respective commutator bar; cutting off said inner and outer edge additions; and connecting together said conductors at said gap, at said outer edge, and at said inner edge, thereby forming a primary winding element.

2. The method defined in claim 1 wherein said bodies are coplanar annular disks, one received within the other, the punching being carried out in a circle.

3. The method defined in claim 1 wherein said bodies are coaxial tubes of like diameter.

4. The method defined in claim 1, further comprising the steps of similarly forming another such winding element, interposing an insulating spacing body between said other element and the primary element, and connecting the conductors of said elements together at said outer edge and at said gap.

5. The method defined in claim 1, further comprising the steps of forming another such winding element having no commutator bars and terminating at said gap, interposing an insulating spacer body between said other element and said primary element, and connecting said conductors together at said outer edge and at said gap. 

1. A method of making a rotor comprising the steps of: stamping from a metal foil a conductor blank having a plurality of conductors arrayed in groups of at least two said conductors terminating at an inner and outer edge, and said blank terminating with an addition beyond each of said inner and outer edges, said conductors having a commutator bar formed as an extension thereof; laminating a pair of said blanks back to back on a pair of concentric insulating bodies defining a gap juxtaposed with said conductors and adjacent said commutator bars and with said additions extending beyond associated edges of said bodies; punching out at least every second conductor at said gap to leave only one of the conductors of each group connected to its respective commutator bar; cutting off said inner and outer edge additions; and connecting together said conductors at said gap, at said outer edge, and at said inner edge, thereby forming a primary winding element.
 1. A method of making a rotor comprising the steps of: stamping from a metal foil a conductor blank having a plurality of conductors arrayed in groups of at least two said conductors terminating at an inner and outer edge, and said blank terminating with an addition beyond each of said inner and outer edges, said conductors having a commutator bar formed as an extension thereof; laminating a pair of said blanks back to back on a pair of concentric insulating bodies defining a gap juxtaposed with said conductors and adjacent said commutator bars and with said additions extending beyond associated edges of said bodies; punching out at least every second conductor at said gap to leave only one of the conductors of each group connected to its respective commutator bar; cutting off said inner and outer edge additions; and connecting together said conductors at said gap, at said outer edge, and at said inner edge, thereby forming a primary winding element.
 2. The method defined in claim 1 wherein said bodies are coplanar annular disks, one received within the other, the punching being carried out in a circle.
 3. The method defined in claim 1 wherein said bodies are coaxial tubes of like diameter.
 4. The method defined in claim 1, further comprising the steps of similarly forming another such winding element, interposing an insulating spacing body between said other element and the primary element, and connecting the conductors of said elements together at said outer edge and at said gap. 